Coating with primer and topcoat both containing polysulfide, epoxy resin and rubber toughener

ABSTRACT

A process for coating a solid surface comprises 
     1) applying onto a solid surface a primer coating prepared from an amine curing agent, a polysulfide toughening agent, an epoxy resin, a rubber toughening agent, a fire retardant, a glass fiber thixotrope, and a pigment; and 
     2) applying onto the primer coating a topcoat prepared from an amine curing agent, a polysulfide toughening agent, an epoxy resin, a rubber toughening agent, a fire retardant, a glass fiber thixotrope, a pigment and an abrasive aggregate.

Subject to rights of the assignee afforded under a Small BusinessInnovation Research program, the U. S. Government has a paid-up licensein this invention and the right in limited circumstances to require thepatent owner to license others on reasonable terms as provided for bythe terms of contract number N00024-00-C-4080 awarded by the Departmentof the Navy.

BACKGROUND OF INVENTION

This invention pertains to an epoxy useful, for example, as a coatingfor aircraft carrier decks.

It is important that many surfaces are made of a non-skid coating. Forinstance, it is desirable that the deck of an aircraft carrier be madeof a non-skid surface. It is also desirable that such surfaces bedurable. This is particularly true for the portion of the deck where theaircraft take off and land, which is exposed to severe wear. Currently,the aircraft decks are made using solvent-based epoxy coatings, whichare applied so as to form ridges.

The present inventors have recognized, however, that there exists a needfor a more durable coating, and a coating made without solvents. Thepresent inventors have also recognized that a coating lacking volatilesolvents would be desirable so as to avoid use of solvents that can behazardous, and which must be evaporated off to provide the finalcoating.

SUMMARY OF INVENTION

This invention solves one or more of the problems and disadvantagesdescribed above.

In one broad respect, this invention is a process useful for providing acoating for a solid surface, comprising: applying a primer onto thesolid surface to form a primer coating, wherein the primer is preparedfrom an amine curing agent, a polysulfide toughening agent, an epoxyresin, a rubber toughening agent, a fire retardant, a glass fiberthixotrope, and a pigment; applying a topcoat onto the primer coating,wherein the topcoat is prepared from an amine curing agent, apolysulfide toughening agent, an epoxy resin, a rubber toughening agent,a fire retardant, a glass fiber thixotrope, a pigment, and an abrasiveaggregate. As used herein, “coating” may refer to either the primer, thetopcoat, a generic mixture formed from the components described herein,or combinations thereof.

In general, a coating of this invention may be prepared from (formulatedfrom), independently in each occurrence, about 20 to about 60 percent ofthe amine curing agent; about 0.01 to about 30 percent of thepolysulfide toughening agent; about 0.01 to about 15 percent based onthe total weight of the coating of the corrosion inhibitor; about 0.01to about 10 percent based on the total weight of the coating of theglass fiber; about 0.01 to about 3 percent based on the total weight ofthe coating of an moisture penetration inhibitor; about 0.01 to about 35percent based on the total weight of the coating of the fire retardant;about 10 to about 90 percent based on the total weight of the coating ofthe epoxy resin; 4 to about 40 percent based on the total weight of thecoating of the rubber toughening agent; about 0.01 to about 30 percentbased on the total weight of the coating of the pigment about 0.01 toabout 10 percent based on the total weight of the coating of theultraviolet light stabilizer; and/or about 0.01 to about 45 percentbased on the total weight of the coating of the abrasive aggregate.

In one broad respect, this invention is a process useful for providing acoating for a solid surface, comprising: applying a primer onto thesolid surface to form a primer coating on the surface, wherein theprimer is prepared from a first amine side which comprises a mixture ofan amine curing agent, a toughening agent, at least one corrosioninhibitor, a moisture penetration inhibitor, a fire retardant, and aglass fiber thixotrope a first epoxy side which comprises a mixture of:an epoxy resin, a toughening agent, at least one corrosion inhibitor, amoisture penetration inhibitor, a darkening pigment, and a glass fiberthixotrope applying a topcoat onto the primer coating, wherein thetopcoat is prepared from a second amine side which comprises a mixtureof: an amine curing agent, a toughening agent, an ultraviolet lightabsorber and stabilizer, a fire retardant, an infrared light reflectingpigment, a glass fiber thixotrope and impact toughening agent, and anabrasive aggregate, and a second epoxy side which comprises a mixtureof: an epoxy resin, a toughening agent, a glass fiber thixotrope andimpact toughening agent, an ultraviolet light absorber and stabilizer,and an abrasive aggregate.

In one embodiment, the first amine side comprises about 40 to about 60percent of the amine curing agent, about 10 to about 30 percent of thetoughening agent, about 0.01 to about 6 percent of at least onecorrosion inhibitor, about 0.01 to about 5 percent of the glass fiber,about 0.01 to about 3 percent of the moisture penetration inhibitor,and/or about 10 to about 35 percent of the fire retardant.

In one embodiment, the first epoxy side comprises about 50 to about 90percent of the epoxy resin, about 10 to about 40 percent of thetoughening agent, about 0.01 to about 6 percent of the corrosioninhibitor, about 0.01 to about 15 percent of the pigment, and/or about0.01 to about 2 percent of the glass fiber.

In one embodiment, the second amine comprises about 25 to about 50percent of the amine curing agent, about 0.01 to about 10 percent of thetoughening agent, about 0.01 to about 6 percent of the corrosioninhibitor, about 15 to about 25 percent of the pigment, about 0.01 toabout 45 percent of the abrasive aggregate, about 0.01 to about-5percent of the glass fiber, and/or about 5 to about 15 percent of thefire retardant.

In one embodiment, the second epoxy side comprises about 20 to about 45percent of the epoxy resin, about 8 to about 20 percent of thetoughening agent, about 0.01 to about 6 percent of the corrosioninhibitor, about 0.01 to about 10 percent of the ultraviolet lightstabilizer, about 0.01 to about 15 percent of the pigment, and/or about0.01 to about 5 percent of the glass fiber.

In another broad respect, this invention is an epoxy topcoat comprisinga cured mixture that is formulated from an epoxy resin, a polysulfidetoughening agent, optionally, an ultraviolet light stabilizer, apigment, a glass fiber thixotrope, an abrasive aggregate, a fireretardant, an amine curing agent, and a rubber toughening agent.

In another broad respect, this invention is an epoxy primer comprising acured mixture that is made from an amine curing agent, a polysulfidetoughening agent, a fire retardant, a glass fiber thixotrope an epoxyresin, a rubber toughening agent, a pigment, optionally, a corrosioninhibitor, and optionally, a moisture penetration inhibitor.

In another broad respect, this invention is a process useful forproviding a coating for a solid surface, comprising: applying a coatingonto the solid surface, wherein the coating is prepared from an amineside which comprises a mixture of: an amine curing agent, a polysulfidetoughening agent; and an epoxy side which comprises a mixture of: anepoxy resin, a rubber toughening agent, and wherein the coating is alsoprepared from a fire retardant, a glass fiber thixotrope, a pigment, andan abrasive aggregate, and wherein the surface may be primed orun-primed prior to application of the topcoat.

The primer is used to promote adhesion of the non-skid topcoat and toinhibit corrosion of a metal substrate to which the primer may beapplied. Either or both of the primer sides may include an ultravioletlight absorber and stabilizer. In one embodiment, the second amine sideor the second epoxy side or both may include a pigment, such as adarkening pigment. In one embodiment the epoxy side and amine sideinclude different pigments (e.g., one is white and one is black) toassist the user in achieving adequate mixing of the two sides.

In one embodiment, the topcoat is applied in a manner such that aplurality of ridges are formed by the topcoat such as by rolling,trowelling, raking or spraying. The rolling can be through use of aphenolic napless roller of a design such that upon application, ridgesand valleys are formed to supply additional slip resistance. For manyapplications, the topcoat may be applied using one gallon of topcoat forevery 20-30 square feet of surface to be coated. The topcoat may beapplied to the primer as soon as the primer is cured to a tack freestate. Typically, the topcoat is tack free within 1 to 48 hours afterbeing applied, depending on temperature and other conditions. Ingeneral, hotter ambient temperatures lead to shorter tack free times.

In another broad respect, this invention is a method of manufacturing anepoxy side and an amine side for use in the formation of a coating,comprising: forming a mixture of an amine side from an amine curingagent and a polysulfide toughening agent, forming a mixture of an epoxyside from an epoxy resin and a rubber toughening agent, wherein theamine side is also formed from a fire retardant, a glass fiberthixotrope, a pigment, an abrasive aggregate, a moisture penetrationinhibitor, an ultraviolet light stabilizer, or combination thereof, andwherein the epoxy side is also formed from a fire retardant, a glassfiber thixotrope, a pigment, an abrasive aggregate, a moisturepenetration inhibitor, an ultraviolet light stabilizer, or combinationthereof.

In another broad respect, this invention is a process useful forproviding a coating for a solid surface, comprising: applying a coatingonto the solid surface, wherein the coating is prepared from (a) anamine curing agent, (b) a polysulfide toughening agent, (c) an epoxyresin, (d) a rubber toughening agent, and (e) a fire retardant, a glassfiber thixotrope, a pigment, a corrosion inhibitor, a moisturepenetration inhibitor, an ultraviolet light stabilizer, an abrasiveaggregate, or a combination thereof.

The surfaces to be coated may include metal surfaces such as but notlimited to the deck of a ship, including the deck of an aircraftcarrier, the surface of an oil well drilling platform, and otherindustrial or utility thoroughfares.

The composition may include at least one moisture penetration inhibitorin the first amine side and at least one moisture penetration inhibitorin the first epoxy side. In one embodiment, the primer is white and theepoxy side is black (or vice versa) so that when mixed, a gray color iscreated. This is advantageous for purposes of handling, mixing, andapplication of the materials.

In one aspect, the toughening agent may be a rubber toughening agent ora polysulfide toughening agent.

In one respect, the abrasive aggregate is comprised of a mixture ofcoarse aluminum powder and aluminum pellets.

In another respect, this invention is a coating composite formed byapplication of a topcoat layer to a primer layer. The topcoat and primermay be made from the epoxy and amine sides described herein. Thelaminate can thus be described as a composition comprising a topcoatlayer adhered or bonded to a primer layer.

In another broad respect, this invention is a process useful for makinga non-skid coating kit, comprising a first amine side and first epoxyside of a primer and a second amine side and a second epoxy side of atopcoat, wherein the process comprises: (a) combining an amine curingagent, a toughening agent, a corrosion inhibitor, and fire retardant toform the first amine side; adding the first amine side to a firstcontainer and then sealing the container; (b) combining an epoxy resin,a toughening agent, a corrosion inhibitor, an ultraviolet lightstabilizer, a pigment, and a thixotrope glass fiber reinforcing agent toform the first epoxy side; adding the first epoxy side to a secondcontainer and then sealing the container; (c) combining an amine curingagent, a rubber toughening agent, a corrosion inhibitor, an ultravioletlight reflector, a fire retardant, a thixotrope glass fiber reinforcingagent to form the second amine side to a container and then sealing thecontainer; and (d) combining an epoxy resin, a toughening agent, apigment, a thixotrope glass fiber reinforcing agent, an ultravioletlight absorber and stabilizer, and an aggregate to form the second epoxyside; adding the second epoxy side to a second container and thensealing the container.

This invention thus provides a coating useful for applications such asbut not limited to the deck of an aircraft carrier. Advantageously, thecoating may be made from 100% solids components obtained from a supplierwithout further dilution, i.e., without the addition of volatilesolvents. As used herein, a solvent such as water or an organic compoundrefers to materials that dissolves the epoxy resin and/or amine startingmaterials, and which evaporates from the coating upon application and/orexposure to an open environment (such as to air). Representativeexamples of such volatile organic solvents that may be advantageouslyabsent from the components used to make the final coating include lowmolecular weight halogenated hydrocarbons such as chloroform and carbontetrachloride, hydrocarbons, alcohols, ketones, ethers, glycol ethers,and so forth. In the practice of this invention, the starting materialsand final cured coating are substantially free of solvents, containingat most only minor amounts of such solvents and no more than about 40percent of the component weight. Advantageously, the coating hasexcellent durability and has improved durability relative to thesolvent-based coatings currently in use.

The type of substrates and surfaces on which the coating of thisinvention may be used vary widely. For example, the type of surfacesthat can be treated with the coating of this invention includes glass,ceramics, metals, and plastics. Typically, the surface is metal.

DETAILED DESCRIPTION OF THE INVENTION

The final cured coating of this invention has a thickness which can varywidely depending on the end use. In general, the coating has a thicknessof from about 0.1 cm to about 2 cm, though thicknesses above and belowthese thicknesses are anticipated.

The epoxy resin used in the practice of this invention may vary andincludes conventional, commercially available epoxy resins. Two or moreepoxy resins may be employed in combination. In general, the epoxyresins can be glycidated resins, cycloaliphhatic resins, epoxidizedoils, and so forth. The glycidated resins are frequently the reactionproduct of a glycidyl ether, such as epichlorohydrin, and a bisphenolcompound such as bisphenol A. C₄-C₂₈ alkyl glycidyl ethers; C₂-C₂₈alkyl-and alkenyl-glycidyl esters; C₁-C₂₈ alkyl-, mono- and poly-phenolglycidyl ethers; polyglycidyl ethers of pyrocatechol, resorcinol,hydroquinone, 4,4′-dihydroxydiphenyl methane (or bisphenol F),4,4′-dihydroxy-3,3′-dimethyldiphenyl methane, 4,4′-dihydroxydiphenyldimethyl methane (or bisphenol A), 4,4′-dihydroxydiphenyl methylmethane, 4,4′-dihydroxydiphenyl cyclohexane,4,4′-dihydroxy-3,3′-dimethyldiphenyl propane, 4,4′-dihydroxydiphenylsuflone, and tris (4-hydroxyphynyl)methane; polyglycidyl ethers of thechlorination and bromination products of the above-mentioned diphenols;polyglycidyl ethers of novolacs; polyglycidyl ethers of diphenolsobtained by esterifying ethers of diphenols obtained by esterifyingsalts of an aromatic hydrocarboxylic acid with a dihaloalkane ordihalogen dialkyl ether; polyglycidyl ethers of polyphenols obtained bycondensing phenols and long-chain halogen paraffins containing at leasttwo halogen atoms; N,N′-diglycidyl-aniline;N,N′-dimethyl-N,N′-diglycidyl-4,4′-diaminodiphenyl methane;N,N,N′,N′-tetraglycidyl-4,4′-diaminodiphenyl methane;N,N′-diglycidyl-4-aminophenyl glycidyl ether;N,N,N′,N′-tetraglycidyl-1,3-propylene bis-4-aminobenzoate; phenolnovolac epoxy resin; cresol novolac epoxy resin; and combinationsthereof. Representative non-limiting examples of epoxy resins useful inthis invention include bis-4,4′-(1-methylethylidene) phenol diglycidylether and (chloromethyl) oxirane Bisphenol A diglycidyl ether.Commercially available epoxy resins that can be used in the practice ofthis invention include but are not limited to arildite GY6010 and Epon828. The epoxy resin can be used in any amount effective to form acoating of this invention. In general, the amount of epoxy resin used inthe first epoxy side for the primer is from about 50 to about 90 percentby weight, and from about 20 to about 45 percent in the second epoxyside for topcoat. The epoxy resin is thinner than the type of resin usedto make solvent-based epoxy coatings. Typically, the epoxy resin has aviscosity of from about 11,000 to about 14,000.

The toughening agent used in the practice of this invention providestoughening and durability characteristics to the coating. By tougheningit is meant that the material has imparted to it a greater impactstrength. The toughening agent may be selected from conventionaltoughening agents such as rubber toughening agents and polysulfidetoughening agents. The toughening agent can vary. The polysulfidetoughening agent may be an epoxy terminated polysulfide polymer. Onerepresentative formula for such materials is:

where n may be from 1 to 1,000. It is believed that the polysulfidetoughening agent reacts during the epoxy curing to the amine function ofthe curing agent. Such compounds are well known, and are currentlyavailable commercially under the tradename ELP-3, sold by Rohm & Haas.The polysulfide toughening agent is epoxy terminated and can react withthe amine curing agent, but is stable in the epoxy resin. A tougheningagent functions to improve impact resistance. Toughening agents functionby forming a secondary phase within the polymer matrix. This secondaryphase is rubbery and hence is capable of crack growth arrestment. Thiscrack arresting function provides improved impact toughness.

A representative example of a rubber toughening agents includesamine-terminated butadiene nitrile (ATBN) and carboxy-terminatedbutadiene nitrile (CTBN). ATBN is amine terminated so that it can reactwith the epoxy functionality and is stable upon mixture with an aminecuring agent. A representative example of a polysulfide toughening agentis an epoxy- terminated polysulfide toughening agent. The ability ofATBN or the polysulfide toughening agent to react with their resincomplements allows for good chemical bonding between separate phases(rubber and resin).

The abrasive aggregate may be selected from a wide variety of materials.The abrasives are employed in amounts effective to-provide additionalanti-skid properties to the coating. Representative examples of suchabrasives include metals such as aluminum, pumice, garnet, silica,ceramic fibers or whiskers such as of magnesium oxide, aluminum nitride,boron nitride, zinc oxide, aluminum oxide, quartz, polymer, rubber, andcombinations thereof. The aggregate is employed in a wide range ofamounts. In general, the aggregate is used in an amount of from about 20to about 50 percent by weight of the second amine side, and from about25 to about 60 percent of second epoxy side. The aggregate serves toprovide filler material and an abrasive surface.

The coating of this invention includes a glass fiber, which providesboth thixotropic rheology modification as well as an impact tougheningagent. Such glass fibers include those having an average fiber diameterof about 0.2 to about 5 microns and a surface area as measured by BET ofabout 0.01 to about 25 meters squared per gram (m²/g). In oneembodiment, the BET is about 0.3 to about 6.25 m²/g. In the first amineside, the amount of glass fiber may be from about 0.01 to about 5percent; from about 0.01 to about 2 percent for the first epoxy side;from about 0.01 to about 5 percent for the second amine side, and fromabout 0.01 to about 5 percent for the second epoxy side.

For the primers, one or more corrosion inhibitors may be included. Theseserve to reduce the amount of corrosion of a metal substrate at theprimer/surface interface. A wide variety of such corrosion inhibitorsmay be used. Representative examples of such corrosion inhibitorsinclude zinc-based inhibitors such as zinc phosphate,zinc-5-nitro-isophthalate, zinc molybdate, and zinc oxide andhydrophobic, moisture penetration inhibitors such as hydrophobic,amorphous fumed silica. These may be used in any amount effective toprovide corrosion inhibition.

In the practice of this invention, a UV light stabilizer may beincluded. This serves to protect the cured coating from the harmfuleffects of UV light. Representative examples of such stabilizers includesterically hindered piperidine derivatives including an alkylsubstituted hydroxy piperidines such as dimethyl sebacate,methyl-1,2,2,6,6-pentamethyl-4-piperidinyl sebacate, bis(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate, and1,2,2,6,6-pentamethyl-4-piperidinol. This may be used in any amounteffective to provide UV stabilization.

The coating can include one or more pigments to provide any desiredcolor. The pigments can vary, depending on the desired color of thefinal coating. For example, if a gray coating is desired, white andblack pigments can be used. If a yellow coating is desired, then yellowpigments can be employed, and so on. A representative example of adarkening pigment is black iron oxide. Black iron oxide also has thedesirable property of being infrared transparent and thus may serve asan IR transparent darkening agent. This is beneficial because infraredabsorption by the coating causes the surface temperature to rise, whichis undesirable. Likewise, an IR reflector may be included in thecoatings of this invention. One such IR reflector is titanium dioxide,which may also serve as a pigment. By reflecting IR light, the coatingis less prone to becoming heated in sunlight.

Various fire retardants may be used in the practice of this invention.Common fire retardants include an alumina such as alumina trihydrate,magnesium hydroxide, bismuth oxide, zinc borate, potassiumtripolyphosphate, and antimony oxide. Combinations of these fireretardants can be employed, such as magnesium hydroxide with alumnatrihydrate, and zinc borate with magnesium hydroxide and/or alumnatrihydrate. Fire retardants that are not a known carcinogens arepreferred in the practice of this invention. In general, the fireretardants may be employed in an amount of from about 5 to about 40percent by weight based on the total weight of a given formulation.

On the amine side of the primer and topcoat, an amine curing agent isemployed. Various polyamines can be used for this purpose, includingaliphatic and aromatic amines, cycloaliphatic amines, a Lewis base or aMannich base. For example, the aliphatic amine and cycloaliphatic aminesmay be alkylene diamines such as ethylene diamine, propylene diamine,1,4-diaminobutane, .1,3-diaminopentane, 1,6-diaminohexane,2,5-diamino-2,5-dimethylhexane, 2,2,4-trimethyl- 1 ,6-diaminohexane, 1,11 -diaminoundecane, 1, 1 2-diaminododecane, 1,3- or 1,4-cyclohexamediamine, 1 -amino-3,3,5-trimethyl-5-amininomethyl-cyclohexane, 2,4- or2,6-hexahydrotolvylene diamene 2,4′- or 4,4′-diaminodicyclohexylmethane, 3,3′-dialkyl-4,4′-diamino-dicyclohexyl methaneisophoronediamine, trimethylhexamethylene diamine, triethylene diamine,piperazine-n-ethylamine, polyoxyalkylene diamines made from propyleneoxide and/or ethylene oxide. Commercially available amine curing agentsmay sometimes include residual amounts of solvents such as benzylalcohol used in the manufacture of the compounds. The aromaticpolyamines may include 2,4- or 2,6-diaminotoluene and 2,4′- or4,4′-diaminodiphenyl methane. Mixtures of amine curing agents may beemployed. The amount of amine curing agent may vary depending on theamount of epoxy resin to be cured. In general, the amount of aminecuring agent employed is so that the volumetric ratio of an amine sideto an epoxy side is from about 30:70 to about 70:30, with a weight ratioof from about 1:15 to 15:1 being most typical. Typically, the mole ratioof amine curing agent to the epoxy resin is in the range from about 0.25to about 2.5, and in one embodiment is about 1:1.

The following examples are illustrative of this invention and are notintended to be limiting as to the scope of the invention or claimshereto. Unless otherwise denoted all percentages are by weight of thetotal part (i.e., the primer epoxy or topcoat amine and so forth).

EXAMPLE 1

A primer and topcoat were prepared containing the components andrespective amounts shown in Tables 1a and 1b. Each of the sides wasthoroughly mixed prior to application onto a metal surface. Thecomponents were mixed using low shear (1000 RPM), and when all thecomponents have been added, the speed was increased to 2000-2500 RPM. Inthe table, the Lauscha Fiber International B-1 5-F (a thixotrope glassfiber reinforcing agent) has a BET of 1.08 square meters per gram, and anominal diameter of-1.48 microns.

TABLE 1a Primer Composition Amine Side Epoxy Side Weight WeightSupplier/Tradename/ Component Percent Supplier/Tradename/ ComponentPercent Vantico Hardner Amine Curing Agent 49.0 Vantico Epoxy Resin 69.4HY 2963 Cyclohexanemethanamine, 5- Araldyte GY6010 Phenol,4,4′-(1-methylethylidene)bis-, amino-1,3,3-trimethyl- polymer with(chloromethyl)oxirane Isophoronediamine Bisphenol A Diglycidyl EtherPolymer Bisphenol A B. F. Goodrich Rubber Toughening Agent 17.0 Rohm &Haas Polysulfide Toughening Agent 23.5 Hycar 1300X16 ATBN ELP-3 Epoxyterminated polysulfide Aminoethyl piperazine Sherwin-Williams CorrosionInhibiter 1.4 Sherwin-Williams Corrosion Inhibiter 0.6 MolyWhite 101Zinc Molybdate MolyWhite 101 Zinc Molybdate Zinc Oxide Zinc Oxide AlcanChemicals Fire Retardant 11.2 Rockwood Industries Corrosion Inhibitor0.3 Alumina Trihydrate Al₂O₃.3H₂O Phos Plus Zn₃(PO₄)₂-2, -4 H₂O MixtureH-10 Laurel Industries Inc. Fire Retardant 20.6 Heucotech CorrosionInhibitor 0.03 Fireshield ® Sb₂O₃ Heucorin RZ Zinc-5-Nitro-Iso PhthalateDegussa Hydrophobic Moisture 0.9 Degussa Hydrophobic MoisturePenetration 0.5 Aerosil 812 Penetration Inhibitor Aerosil 812 InhibitorAmorphous Fumed Silica Amorphous Fumed Silica Ferro UV Light Stabilizer2.0 UV 55-07051 Bis(1,2,2,6,6-Pentamethyl-4- Piperidinyl)SebacateLaPorte Darkening Pigment 1.2 Black Iron Oxide Fe₃O₄ Lauscha FiberThixotrope 1.4 Internat. Glass Fiber Reinforcing Agent B-15-F Total100.1 98.93

TABLE 1b Top-Coat Composition Amine Side Epoxy Side Weight WeightSupplier/Tradename Component Percent Component Supplier/TradenamePercent Air Products Amine Curing Agent 39.5 Vantico Epoxy Resin 48.4Ancamime 2074 Isophoronediamine Araldyte GY6010 Phenol, 4,4′-(1-Trimethylhexamethylenediamine methylethylidene)bis-, polymer with(chloromethyl)oxirane Bisphenol A Diglycidyl Ether Polymer B. F.Goodrich Rubber Toughening Agent 3.9 Rohm & Haas Polysulfide TougheningAgent 16.1 Hycar 1300X16 ATBN ELP-3 Epoxy terminated polysulfideAminoethyl piperazine Ribelin Sales Corrosion Inhibitor; UV Reflector7.9 LaPorte Darkening Pigment 4.8 Zinc Oxide (Grade ZnO Black Iron OxideFe₃O₄ 210) Alcan Chemicals Fire Retardant 4.7 Lauscha Fiber Internat.Thixotrope 1.9 Alumina Trihydrate Al₂O₃.3H₂O B-15-F Glass FiberReinforcing Agent H-10 Laurel Industries Fire Retardant 4.7 Ferro UVLight Stabilizer 2.0 Inc. Sb₂O₃ UV 55-07051 Bis(1,2,2,6,6-Pentamethyl-4-Fireshield ® Piperidinyl)Sebacate Kronos Pigment 11.8 Atlantic EquipmentEng. Aggregate 25.8 Titanium Dioxide Aluminum Powder Aluminum P25Lauscha Fiber Thixotrope 1.6 Internal. Glass Fiber Reinforcing AgentB-15-F Atlantic Equipment Aggregate 26.1 Eng. Aluminum Aluminum PowderTotal 100.2 99

Thus, the first amine side and first epoxy side were combined and mixed,then applied to a metal surface using a phenolic napless roller tothereby form a primed surface. After the primer has cured to a tack freestate, the second amine side and the second epoxy side are mixed andapplied to the primed surface using a phenolic napless roller. Thesurface can be cleaned prior to application of the primer. The rheologyof the topcoat allows for the formation of the ridges and valleys whichsupplies additional slip resistance. The resulting coating wasapproximately 1-10mm thick (1-2 mm of primer). The coating exhibitedexcellent durability when subjected to a standard impact test. Thecoating showed surprisingly little wear due to the impact. The impacttest, conducted according to MIL-PRF-24667A (Navy), consists of droppinga 907 gram steel ball from a height of 244cm onto the coated steelsurface onto a coated steel plate in a 5 by 5 array consisting of 25impacts. Impact resistance is scored by counting the number of adjacentimpact points where coating has been removed, mutiplying this number by2.5 percentage points and subtracting this from 100. A minimum score of95% is expected for acceptable material according to MIL-PRF-24667A(Navy). The coatings described herein typical score 100 in this test.

EXAMPLE 2

The procedures of Example 1 were repeated except that the primer andtopcoat of Tables 2a and 2b were employed. In this example, antimonyoxide and zinc oxide were removed from the coating of Tables 1 a and1-b, with alumina trihydrate and titanium dioxide being used instead.Also, the zinc corrosion inhibitors were used in the primer amine sideand some of the glass fiber was moved from the primer epoxy side to theprimer amine side. Likewise, the amounts of zinc corrosion inhibitor andblack iron oxide were increased in the primer epoxy side.

TABLE 2a Primer Composition Amine Side Epoxy Side Weight WeightSupplier/Tradename Component Percent Supplier/Tradename ComponentPercent Vantico Hardner Amine Curing Agent 49.0 Vantico Epoxy Resin 69.4HY 2963 Cyclohexanemethanamine, Araldyte GY6010 Phenol, 4,4′-(1-5-amino-1,3,3-trimethyl- methylethylidene)bis-, polymer withIsophoronediamine (chloromethyl)oxirane Bisphenol A Bisphenol ADiglycidyl Ether Polymer B. F. Goodrich Rubber Toughening Agent 17.0Rohm & Haas Polysulfide Toughening Agent 23.5 Hycar 1300X16 ATBN ELP-3Epoxy terminated polysulfide Aminoethyl piperazine Sherwin-WilliamsCorrosion Inhibiter 2.24 Sherwin-Williams Corrosion Inhibiter 0.6MolyWhite 101 Zinc Molybdate MolyWhite 101 Zinc Molybdate Zinc OxideZinc Oxide Alcan Chemicals Fire Retardant 31.8 Rockwood IndustriesCorrosion Inhibitor 0.7 Alumina Trihydrate Al₂O₃.3H₂O Phos PlusZn₃(PO₄)₂-2, -4 H₂O Mixture H-10 Degussa Hydrophobic Moisture 0.9Heucotech Corrosion Inhibitor 0.03 Aerosil R812 Penetration InhibitorHeucorin RZ Zinc-5-Nitro-Iso Phthalate Amorphous Fumed Silica LauschaFiber Thixotrope 1.0 Degussa Hydrophobic Moisture Penetration 0.5Internat. Glass Fiber Reinforcing Aerosil R812 Inhibitor B-15-F AgentAmorphous Fumed Silica Ferro UV Light Stabilizer 2.0 UV 55-07051Bis(1,2,2,6,6-Pentamethyl-4- Piperidinyl)Sebacate LaPorte IRTransparent, Darkening Pigment 1.7 Black Iron Oxide Fe₃O₄ Lauscha FiberThixotrope 0.3 Internat. Glass Fiber Reinforcing Agent B-15-F Total100.1 98.93

TABLE 2b Top-Coat Composition Amine Side Epoxy Side Weight WeightSupplier/Tradename Component Percent Supplier/Tradename ComponentPercent Air Products Amine Curing Agent 39.5 Vantico Epoxy Resin 48.4Ancamime 2074 Isophoronediamine Araldyte GY6010 Phenol, 4,4′-(1-Trimethylhexamethylenediamine methylethylidene)bis-, polymer with(chloromethyl)oxirane Bisphenol A Diglycidyl Ether Polymer B. F.Goodrich Rubber Toughening Agent 3.9 Rohm & Haas Polysulfide Toughening16.1 Hycar 1300X16 ATBN ELP-3 Agent Aminoethyl piperazine Epoxyterminated polysulfide Alcan Chemicals Fire Retardant 9.4 LaPorte IRTransparent Darkening 4.8 Alumina Trihydrate Al₂O₃.3H₂O Black Iron OxidePigment H-10 Fe₃O₄ Kronos — Titanium Pigment and IR Reflector 19.7Lauscha Fiber Internat. Thixotrope Glass Fiber 1.9 Dioxide P25 B-15-FReinforcing Agent Lauscha Fiber Thixotrope 1.6 Ferro UV Light Stabilizer2.0 Internat. Glass Fiber Reinforcing UV 55-07051 Bis(1,2,2,6,6- B-15-FAgent Pentamethyl-4- Piperidinyl)Sebacate Atlantic Equipment Aggregate26.1 Atlantic Equipment Eng. Aggregate 25.8 Eng. Aluminum AluminumPowder Aluminum Aluminum Powder Total 100.2 99

The primer sides and topcoat sides were applied to a clean steel platesubstrate according to Example 1. The cured coating was subjected to theimpact test of Example 1. The cured coating showed excellent durabilityand surprisingly little wear.

Further modifications and alternative embodiments of this invention willbe apparent to those skilled in the art in view of this description.Accordingly, this description is to be construed as illustrative onlyand is for the purpose of teaching those skilled in the art the mannerof carrying out the invention. It is to be understood that the forms ofthe invention herein shown and described are to be taken as illustrativeembodiments. Equivalent elements or materials may be substituted forthose illustrated and described herein, and certain features of theinvention may be utilized independently of the use of other features,all as would be apparent to one skilled in the art after having thebenefit of this description of the invention.

What is claimed is:
 1. A process useful for providing a coating for asolid surface, comprising: applying a primer onto the solid surface toform a primer coating, wherein the primer is prepared from an aminecuring agent, a polysulfide toughening agent, an epoxy resin, a rubbertoughening agent, a fire retardant, a glass fiber thixotrope, and apigment; applying a topcoat onto the primer coating, wherein the topcoatis prepared from an amine curing agent, a polysulfide toughening agent,an epoxy resin, a rubber toughening agent, a fire retardant, a glassfiber thixotrope, pigment, and an abrasive aggregate.
 2. The process ofclaim 1 wherein the topcoat is also prepared from an ultraviolet lightstabilizer.
 3. The process of claim 1 wherein the primer is alsoprepared from a corrosion inhibitor.
 4. The process of claim 1 whereinthe primer is also prepared from a moisture penetration inhibitor. 5.The process of claim 1, wherein the topcoat is applied in a manner suchthat a plurality of ridges are formed by the topcoat.
 6. The process ofclaim 1, wherein the surface is a deck of a ship.
 7. The process ofclaim 1, wherein the surface is a metal surface.
 8. The process of claim1, wherein the surface is a deck of an aircraft carrier.
 9. The processof claim 1, wherein the surface is on an oil well drilling platform. 10.The process of claim 1, wherein the topcoat is applied by rolling,trowelling, raking, or spraying.
 11. The process of claim 1, wherein theglass fiber has average fiber diameter of about 0.2 to about 5 micronsand a surface area as measured by BET of about 0.01 to about 25 meterssquared per gram.
 12. The process of claim 1, wherein the primer isprepared from about 20 to about 60 percent of the amine curing agent.13. The process of claim 1, wherein the primer is prepared from about 10to about 30 percent of the polysulfide toughening agent.
 14. The processof claim 1, wherein the primer is prepared from about 0.01 to about 15percent based on the total weight of the primer of an corrosioninhibitor.
 15. The process of claim 1, wherein the primer is preparedfrom about 0.01 to about 10 percent based on the total weight of theprimer of the glass fiber.
 16. The process of claim 1, wherein theprimer is also prepared from about 0.01 to about 3 percent based on thetotal weight of the primer of a moisture penetration inhibitor.
 17. Theprocess of claim 1, wherein the primer is prepared from about 5 to about35 percent based on the total weight of the primer of the fireretardant.
 18. The process of claim 1, wherein the primer is preparedfrom about 20 to about 90 percent based on the total weight of theprimer of the epoxy resin.
 19. The process of claim 1, wherein theprimer is prepared from about 5 to about 40 percent based on the totalweight of the primer of the rubber toughening agent.
 20. The process ofclaim 1, wherein the primer is prepared from about 0.01 to about 30percent based on the total weight of the primer of the pigment.
 21. Theprocess of claim 1, wherein the topcoat is prepared from about 10 toabout 50 percent based on the total weight of the topcoat of the aminecuring agent.
 22. The process of claim 1, wherein the topcoat isprepared from about 0.01 to about 10 percent based on the total weightof the topcoat of the polysulfide toughening agent.
 23. The process ofclaim 1, wherein the topcoat is prepared from about 0.01 to about 30percent based on the total weight of the topcoat of the pigment.
 24. Theprocess of claim 1, wherein the topcoat is prepared from about 0.01 toabout 45 percent based on the total weight of the topcoat of theabrasive aggregate.
 25. The process of claim 1, wherein the topcoat isprepared from about 0.01 to about 10 percent of the glass fiber.
 26. Theprocess of claim 1, wherein the topcoat is prepared from about 0.01 toabout 20 percent of the fire retardant.
 27. The process of claim 1,wherein the topcoat is prepared from about 10 to about 45 percent basedon the total weight of the topcoat of the epoxy resin.
 28. The processof claim 1, wherein the topcoat is prepared from about 4 to about 20percent based on the total weight of the topcoat of the rubbertoughening agent.
 29. The process of claim 1, wherein the topcoat isprepared from about 0.01 to about 10 percent based on the total weightof the topcoat of an ultraviolet light stabilizer.
 30. The process ofclaim 1, wherein the primer is also prepared from a moisture penetrationinhibitor.
 31. The process of claim 1, wherein the abrasive aggregate iscomprised of a mixture of aluminum powder and aluminum pellets.
 32. Theprocess of claim 1, wherein the primer and topcoat are substantiallyfree of solvents.